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Materials Joining Technology Advancements for Future
Pipelines
Nate Ames EWI Energy & ChemicalMarket Leader
Roger Howard BPAdvisor – Welding and Materials
+44 1932 [email protected]
Mark Hudson BPWelding and Materials Engineer
+44 1932 [email protected]
Pipeline Welding Circa 1980’s
Application 1980's Predicted Technologies 2005 RealitySMAW
Semi-GMAWSMAW
SMAW SMAW FCAWSemi-GMAW
SMAW SMAWSMAW Mechanical Joining GMAW / FCAW
SAW (Pre-Fab.) MIAB Mech-GMAWFlash SAW (Pre-Fab.)
SMAW Mech-GMAW SMAWMech-GMAW Hot Wire GTAW GMAW / FCAW
SAW (Pre-Fab.) Flash Mech-GMAWSAW (Pre-Fab.)
Fusion Fusion FusionElectroFusion ElectroFusion ElectroFusion
Fusion Fusion FusionElectroFusion ElectroFusion ElectroFusion
Short Pipelines
Tie-Ins
SMAW SMAW
Plastic Pipe (Large Diameter)
Plastic Pipe (Small Diameter)
Long Pipelines (Small Diameter)
Long Pipelines (Large Diameter)
The Future Circa 2005
Will Not Get Easier- Technology Advancements Follow Technology
Requirements• X80 X100 X120 ?• Ambient Temp Arctic Temp Cryogenic Temp• Ambient Temp 200 °C ?• Plastic Pipe 200 psi >800 psi• Increasingly Corrosive Applications
• CRA Solid Pipe and Clad Pipe• Trenchless Repair and Installation• Increasing Productivity Targets
New Viable Technology
Iterative Process ImprovementsMechanized Processes- Statistical Process Control / Data Logging- Improved Feedback Control- Improved Mechanization
New Processes- Hybrid Laser / GMAW- Tandem GMAW (Single & Dual Torch)- Magnetic Pulse Coating Solution- Automated Plastic Pipe Welding
Iterative Process Improvements
Consumables Development- High Strength Pipeline Materials Reciprocate
High Strength Consumables• Hurdles
• Toughness• Diffusible Hydrogen• Strength
SMAW is Here to Stay- Next Generation SMAW
• Oxygen <500 ppm, • H2 - Diff Hydrogen• >100 ksi
- Low Hydrogen Vertical Down vs Cellulosic
Iterative Process Improvements
Equipment Improvements- Power Source Technology- Seam Tracking Technology- Better Integration- Lighter Weight- More Stability (Predictable Outputs)
2.5-in.
Low dilution: Nickel alloy on steel
Statistical Process Control
High Speed Data Acquisition- Video >60,000 frames/sec- Weld Data > 500 Hz
More Variables Collected- Single Sensor Differential Thermal
Analysis (SS-DTA)- Audible Noise- Joint Geometry (Pre-Weld)- Weld Geometry (Post-Weld)
Improved Feedback Control
CTWD ControlTorch Force (X,Y,Z)Weld Pool GeometryWeld Pool OscillationLaser Profilometry- Pre/Post Weld
Machine VisionMachine Vision
Improved Feedback Control
“MBML”- Deployed in Production
Shipbuilding – 2004
Improved Mechanization
Spin Arc / Rotated ElectrodeLead-Lag ControlDual Torch Multi-Function
Hybrid Laser/GMAW
Tandem GMAWBP / TCPL funded development of dual tandem at Cranfield University using Fronius synchronized power sources 2001 - 2002
Dual torch operational field trial Edmonton March 2003
Tandem GMAW
Single tandem employed by CRC with IWM & P-GMAW HP on the TCPL
Godin Lake X100 loop 2004
CRC and Serimer have completed consistency trial on X80 for McKenzie.
Magnetic Pulse Clad Concept
Capacitor bank
Process Description
Magnetic Pulse Clad Concept
Automated Plastic Pipe Welding
Two New Concepts- Heated Friction Tool- Rotating Friction Collar
Rotating Coupler
Concluding Remarks
What Welding Technology is the Next Big Thing- Reality – We don’t know
• Demographics & Unions• Pipe/Steel Development• Application Requirements
- High Probability• Dual Tandem• Hybrid Laser/GMAW
• Utilizing Advanced Seam Tracking• PE and PA Pipe
• Related Joining Technologies
Where do you want pipeline welding to go?
Nate Ames EWI Energy & ChemicalMarket Leader
Roger Howard BPAdvisor – Welding and Materials
+44 1932 [email protected]
Mark Hudson BPWelding and Materials Engineer
+44 1932 [email protected]
